What Is the ABB PM858K02 MPC866 Controller?
When your process demands uninterrupted control, the ABB PM858K02 MPC866 controller provides the reliability you need. This CPU board integrates a microprocessor, RAM memory, real-time clock, LED indicators, INIT push button, and a CompactFlash interface. Designed for System 800xA 6.0.2 and Compact Control Builder 6.0.0-1 onwards, it supports CPU redundancy for higher availability across CPU, CEX-Bus, communication interfaces, and S800 I/O.
The PM858K02 package includes two PM858 CPUs, two TP830 base plates, two TB807 ModuleBus terminators, one TK850 CEX-bus expansion cable, one TK851 RCU-Link cable, and two backup batteries (4943013-6). Each TP830 base plate carries a unique Ethernet address, giving every CPU a hardware identity.
Technical Specifications Breakdown
- Processor Type: MPC866 running at 33 MHz clock frequency delivers 0.36 ms for 1000 boolean operations.
- Memory: 16 MB total with 7.147 MB RAM available for applications and 4 MB Flash PROM for firmware storage.
- Power Supply: 24 V DC (19.2–30 V DC) with typical consumption of 210 mA and maximum 360 mA. Power dissipation is 5.1 W typical, 8.6 W max.
- Communication: Two RJ45 Ethernet ports (10 Mbit/s, IEEE 802.3) for Control Network using MMS and IAC protocols. Two RS-232C serial ports: COM3 (75–19,200 baud, non-isolated, full RTS-CTS) and COM4 (9,600 baud, isolated, for configuration tool).
- Environmental: Operating temperature +5 to +55 °C, storage -40 to +70 °C. IP20 protection per EN 60529. CE marked, ISA Secure certified, and cULus for hazardous locations Class 1 Zone 2.
Industry Applications
In oil and gas refineries, the PM858K02 handles critical process control with its redundant CPU architecture, ensuring minimal downtime. The 32 tasks per controller and cycle times down to 1 ms make it suitable for high-speed batch processes. For power generation plants, the dual Ethernet ports and support for up to 12 communication modules on the CEX bus enable seamless integration with distributed I/O.
Installation & Setup Guidance
Mount the PM858K02 on a DIN rail using the slide & lock mechanism for simple attachment or detachment. Connect the TP830 base plate to the Control Network via the two RJ45 ports (CN1, CN2). Use COM4 for initial configuration with a configuration tool. Ensure the backup battery (3.6 V lithium) is installed before powering up to preserve memory. Only compatible with System 800xA 6.0.2 and Compact Control Builder 6.0.0-1 onwards.
Maintenance & Reliability
With ISA Secure certification and full EMC compliance, the PM858K02 is built for long-term reliability. The built-in backup battery maintains memory during power loss. Periodically inspect the base plate Ethernet address label for hardware identity verification. The redundant power supply status input allows monitoring of power health. For maximum uptime, verify that the ModuleBus terminators (TB807) are properly seated.
Compatibility & Integration
The PM858K02 integrates with S800 I/O via ModuleBus, supporting up to 96 I/O modules with a non-redundant CPU or 84 with redundant CPU. It communicates on the Control Network using MMS and IAC protocols over a recommended 100 Mbit/s switched Ethernet backbone. CEX-Bus supports up to 12 communication modules with a maximum supply current of 2.4 A. The controller also supports PROFIBUS DP via optional modules.
Selection Guide & Purchasing Advice
Before ordering, verify your system software version: the PM858K02 requires System 800xA 6.0.2 or later and Compact Control Builder 6.0.0-1 or later. The package includes all necessary components for a redundant setup: two CPUs, two base plates, terminators, cables, and batteries. SpareTechPLC stocks this controller and can confirm current lifecycle status and availability. Contact us for fast shipping and expert support.
Frequently Asked Questions
Q: What is the switchover time in redundant configuration?
A: The maximum switchover time is 10 ms, ensuring minimal process interruption during CPU failover.
Q: How many I/O modules can the PM858K02 support?
A: With a non-redundant CPU, up to 96 I/O modules on ModuleBus. With redundant CPU, up to 84 modules (all optical).
Q: Does the PM858K02 include batteries?
A: Yes, the package includes two lithium 3.6 V backup batteries (4943013-6), one for each controller.
Q: What communication protocols does the control network use?
A: The Control Network uses MMS (Manufacturing Message Service) and IAC (Inter Application Communication) over Ethernet.
Q: Is the PM858K02 certified for hazardous locations?
A: Yes, it has cULus Class 1, Zone 2, AEx nA IIC T4, ExnA IIC T4Gc X certification.
